Method of manufacturing liquid crystal display device

Abstract

A lower substrate 3 on which an adhesive 1 has been applied and a liquid crystal material 2 has been deposited is held fixedly by vacuum suction with a suction-holding mechanism 5 within a vacuum chamber C. An upper substrate 6 held fixedly by vacuum suction with a suction-holding mechanism 7 is brought opposite to the lower substrate 3 with a predetermined spacing therebetween, and either or both of the substrates is/are brought in proximity with each other for bringing the upper substrate into contact with the adhesive 1 or the liquid crystal material 2 . Both substrates 3, 6 are then moved relative to each other in a direction parallel to the substrate surface for position alignment, and thereafter, the substrates are moved closer to and pressed to each other so that they are affixed together.

What is claimed is:  
     
       1. A method of manufacturing a liquid crystal display device comprising the steps of 
       positioning a first substrate on which an adhesive has been applied and a liquid crystal material has been deposited within a vacuum chamber and holding a lower surface of the first substrate fixedly by vacuum suction;  
       positioning a second substrate within the vacuum chamber, the second substrate of which an upper surface is held fixedly by vacuum suction is brought opposite to the first substrate at a predetermined distance therefrom;  
       applying a vacuum between the first and second substrate;  
       moving one or both of the first and second substrates closer to each other for bringing the second substrate into contact with the adhesive and the liquid crystal material on the first substrate;  
       moving both of the first and second substrates relative to each other in a direction parallel to the substrate surface for position alignment; and  
       moving one or both of the first and second substrates for pressing the substrates to each other, whereby both substrates are affixed together.  
     
     
       2. The method of manufacturing a liquid crystal display device according to claim  1  wherein in the step of bringing the second substrate into contact with the liquid crystal material on the first substrate, the second substrate is positioned at a height where a minute gap exists between the second substrate and the adhesive on the first substrate. 
     
     
       3. The method of manufacturing a liquid crystal display device according to claim  1  wherein a resilient member is interposed between the first substrate and a mechanism for holding the first substrate by vacuum suction. 
     
     
       4. The method of manufacturing a liquid crystal display device according to claim  3  wherein the first substrate is released from the suction hold after the first and second substrates have been affixed together. 
     
     
       5. The method of manufacturing a liquid crystal display device according to claim  1  wherein the first and second substrates are tacked together with a UV-curable adhesive after they are affixed together, and thereafter the first substrate is released from the suction hold, and the vacuum chamber is opened and exposed to atmospheric air. 
     
     
       6. The method of manufacturing a liquid crystal display device according to claim  1  wherein at least one of the first and second substrates is positioned with the use of a location mechanism. 
     
     
       7. The method of claim  1  wherein the steps of positioning the second substrate and applying the vacuum are performed at the same time. 
     
     
       8. A method of manufacturing a liquid crystal display device comprising the steps of 
       positioning a first substrate on which an adhesive has been applied and a liquid crystal material has been deposited within a vacuum chamber and holding a lower surface of the first substrate fixedly by vacuum suction;  
       a second substrate of which upper surface is held fixedly by vacuum suction is brought opposite to the first substrate at a predetermined distance therefrom;  
       applying a vacuum between the first and second substrate;  
       moving one or both of the first and second substrates closer to each other until they are located at a predetermined spacing;  
       moving both of the first and second substrates relative to each other in a direction parallel to the substrate surface for preliminary position alignment;  
       moving one or both of the first and second substrates closer to each other for bringing the second substrate into contact with the adhesive or the liquid crystal material on the first substrate;  
       moving both of the first and second substrates relative to each other in a direction parallel to the substrate surface for position alignment; and  
       moving one or both of the first and second substrates for pressing the substrates to each other, whereby both substrates are affixed together.  
     
     
       9. The method of manufacturing a liquid crystal display device according to claim  8  wherein in the step of bringing the second substrate into contact with the adhesive or the liquid crystal material on the first substrate, the second substrate is positioned at a height where a minute gap exists between the second substrate and the adhesive on the first substrate. 
     
     
       10. The method of manufacturing a liquid crystal display device according to claim  8  wherein a resilient member is interposed between the first substrate and a mechanism for holding the first substrate by vacuum suction. 
     
     
       11. The method of manufacturing a liquid crystal display device according to claim  10  wherein the first substrate is released from the suction hold after the first and second substrates have been affixed together. 
     
     
       12. The method of manufacturing a liquid crystal display device according to claim  8  wherein the first substrate is released from the suction hold after the first and second substrates have been affixed together, the vacuum chamber is opened and exposed to atmospheric air, and both substrates are tacked together with a UV-curable adhesive. 
     
     
       13. The method of manufacturing a liquid crystal display device according to claim  8  wherein the first and second substrates are tacked together with a UV-curable adhesive after they are affixed together, and thereafter the first substrate is released from the suction hold, and the vacuum chamber is opened and exposed to atmospheric air. 
     
     
       14. The method of manufacturing a liquid crystal display device according to claim  8  wherein at least one of the first and second substrates is positioned with the use of a location mechanism. 
     
     
       15. The method of claim  8  wherein the steps of bringing the second substrate to a position opposite the first substrate and applying the vacuum are performed at the same time. 
     
     
       16. A method of manufacturing a liquid crystal display device in a system wherein a substrate is affixed to another substrate on which an adhesive and liquid crystal material have been applied within a vacuum chamber, comprising: 
       applying a vacuum between the substrates in the vacuum chamber;  
       moving one or both of the substrates until one substrate contacts the adhesive on the other substrate;  
       moving the substrates relative to each other for position alignment; and  
       pressing the substrates against each other so that they are affixed together.  
     
     
       17. A method of manufacturing a liquid crystal display device in a system wherein a substrate is affixed to another substrate on which an adhesive and liquid crystal material have been applied within a vacuum chamber, characterized by evacuating the vacuum chamber so that a vacuum exists, the substrates are brought into close proximity to each other, and the substrates are preliminarily aligned to each other, and one or both of the substrates is/are moved until one substrate contacts the adhesive on the other substrate, after which the substrates are moved relative to each other for position alignment, and the substrates are pressed to each other so that they are affixed together. 
     
     
       18. The method of claim  17  wherein the steps of bringing the substrates into close proximity and applying the vacuum are performed at the same time. 
     
     
       19. A method of manufacturing a liquid crystal display screen comprising the steps of: 
       positioning a first substrate;  
       applying an adhesive to a portion of a surface of the first substrate;  
       applying a liquid crystal material onto the surface of the first substrate;  
       positioning a second substrate with a surface above and opposite the first substrate surface;  
       applying a vacuum to the space between the first and second substrate;  
       moving the first and second substrates closer to each other to a predetermined vertical alignment distance within the vacuum;  
       moving the first and second substrates relative to each other in a direction parallel to the respective substrate surfaces for positional alignment; and  
       moving the first and second substrates together to enable the adhesive to secure the respective surfaces at a predetermined offset distance for operatively providing the liquid crystal material in contact with the opposing substrate surfaces.  
     
     
       20. The method of claim  19  wherein the step of applying a vacuum is within a vacuum chamber as the second substrate is positioned above the first substrate and further including steps of releasing the vacuum after moving the first and second substrates together to enable the adhesive to secure the respective surfaces and a step of irradiating the adhesive to cure it.